High water hard bars comprising combination of type and amount of electrolytes

Abstract

The invention relates to a process to make high water bars with a high speed extrusion process by using specific types and amounts of electrolytes in combination. The bars are produced with no negatives generally associated with use of electrolytes. Disclosed is an extruded soap bar composition wherein the bar comprises: a) 20 to 40% of water; b) 20 to 75% by wt. anhydrous soap; wherein C16 to C24 saturated soap comprises 12% to 45% by wt. of total bar. c) structurants comprises at least from 0.05 to 35% by wt., wherein the specific level of structurants is defined by the level of C16 to C24 saturated soap of (b) such that the total level of said C16 to C24 saturated soap and structurants are greater than 25%, and wherein said structurants are selected from the group consisting of starch, carboxymethylcellulose, inorganic particulates, acrylate polymers and mixtures thereof; d) electrolyte which is a combination of alkali metal chloride; and a secondary electrolytes selected from the group consisting of alkali metal citrate and alkali metal sulfate; and wherein the concentration of alkali metal chloride ([alkali metal chloride]); and of alkali metal citrate ([alkali metal citrate]), alkali metal sulfate ([alkali metal sulfate]) defined by level of water we use as follows: i. [alkali metal chloride]%=0.075×[water]−0.626; and ii. [alkali metal citrate]%=−0.0023×[water]2+0.312×[water]−4.34; iii. [alkali metal sulfate]%=−0.0023×[water]2+0.312×[water]−4.34; or iv. [alkali metal citrate and alkali metal sulfate]=−0.0023×[water]2+0.312×[water]−4.34, wherein the calculated amount of the concentration of the electrolyte is plus or minus 15%.

The invention claimed is: 
     
       1. An extruded soap bar composition, comprising:
 a) 25 to 40% of water; 
 b) 20 to 75% by wt. anhydrous soap; wherein C 16  to C 24  saturated soap comprises 12% to 45% by wt. of total bar, 
 c) structurants comprises at least from 0.05 to 35% by wt., wherein the specific level of structurants is defined by the level of C 16  to C 24  saturated soap of (b) such that the total level of said C 16  to C 24  saturated soap and structurants are greater than 25%, and wherein said structurants are selected from the group consisting of starch, carboxymethylcellulose, inorganic particulates, acrylate polymers and mixtures thereof; 
 d) electrolyte which is a combination of alkali metal chloride and a secondary electrolyte selected from the group consisting of alkali metal citrate and alkali metal sulfate; and wherein the concentration of alkali metal chloride ([alkali metal chloride]); and of alkali metal citrate ([alkali metal citrate]) or alkali metal sulfate ([alkali metal sulfate]) defined by level of water as follows:
 i. [alkali metal chloride]%=0.075×[water]−0.626; and 
 ii. [alkali metal citrate]%=−0.0023×[water] 2 +0.312×[water]−4.34; 
 iii. [alkali metal sulfate] %=−0.0023×[water] 2 +0.312×[water]−4.34; or 
 iv. [alkali metal citrate or alkali metal sulfate or alkali metal citrate plus alkali metal sulfate]=−0.0023×[water] 2 +0.312×[water]−4.34, 
 
 wherein the calculated amount of the concentration of the electrolyte is plus or minus 15% by wt. 
 
     
     
       2. The extruded soap bar composition as claimed in  claim 1 , wherein the calculated amount of the concentration of the electrolyte is plus or minus 10% by wt. 
     
     
       3. The extruded soap bar composition according to  claim 1 , wherein the ratio of [soap] to [water], is 0.5:1 to 5:1. 
     
     
       4. The extruded soap bar composition according to  claim 1 , wherein the inorganic particulates are talc, calcium carbonate, zeolite or mixtures thereof. 
     
     
       5. The extruded soap bar composition according to  claim 1 , wherein the bar has a hardness value of 1.2 Kg to 5.0 Kg (measured at 40° C. with a 30° conical probe having a penetration depth of 15 millimeters. 
     
     
       6. The extruded soap bar composition according to  claim 1 , wherein the bar has a stickiness value less than 3 as measured by tactile feel test. 
     
     
       7. The extruded soap bar composition according to  claim 1 , wherein the bar has a cracking value of 3 or less as measured by visual assessment after at least 8 days. 
     
     
       8. The extruded soap bar composition of  claim 3 , wherein the ratio is 1:1 to 3:1. 
     
     
       9. The extruded soap bar composition of  claim 8 , wherein the ratio is 1:1 to 2:1. 
     
     
       10. The extruded soap bar composition of  claim 3 , further comprising water soluble solvent, wherein the ratio of [soap] to [water plus water soluble solvent] is 0.5:1 to 5:1.